You guys are all barking up the wrong tree IMHO... The center axle disconnect that breaks the front passenger side axle shaft on the 95-96 model year 4x4s is likely either failing to lock, or popping out when under load. That's where I'd start looking first.
Options? Swap the front axle assembly with one from a 97-01 that doesn't use the CAD, or adapt a unit from 4x4 posi-lok that fits a 97-03 F-150 to manually lock the shift fork in place. Those would be my best two suggestions.
That is, of course, assuming the transfer case is, in fact, locking up solid. No way to know that for sure across the interweb.
-Joe